1997 Voyager Xii: Splitting Engine Cases.... Starter Clutch

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oldmanrock
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1997 Voyager Xii: Splitting Engine Cases.... Starter Clutch

Post by oldmanrock »

Hey all,

NOTE: I have sent an e-mail to Carl as well but wanted to see if anyone has run into this hang up while splitting the engine cases.

First off, total PITA just for the damn starter clutch (excessive slippage)... Here in AZ, so hot these days don't feel like riding so no better time to get the starter clutch swapped out....

I have the engine out of the frame, all case bolts and associated components removed and can get the cases apart everywhere but one place.... :tho:

As can be reviewed in the image, catching/hanging up in the lower case under the flywheel and I can't see anything that would be catching nor any additional bolts (external or internal) that would not allow for the cases to split...

Everywhere along the cases no issues, only in this spot where it will only split apart ~ 3/8ths " and that's it....

Anyone have experienced this or have an idea...?

Thanks,

Dave


Damn image insertion.....
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Gator Mike
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Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu

Post by Gator Mike »

Dave do you have a manual? I split the case on mine about a year ago and we missed a bolt near where the starter is located. After we had trouble we used the manual which pointed out the location of all the bolts. It's amazing how well it went when we followed directions :gig: Anyhow I don't know if that's your problem because once the bolts were out it split real easily. Good luck with what ever it is..........Gator Mike
"Laisez les bon temps rouler!"

1994 Voyager XII
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oldmanrock
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Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu

Post by oldmanrock »

Yup OEM manual (only way to go).... No mention of the hang up so spoke with Carl (great guy)....

Anyway, turns out the flywheel does indeed have to come off....
Starter clutch already swapped out... Old one spins both ways by hand... DOH! :-O
Tranny gears, bearings, clutch components, oil pump components etc... all look good.

Cleaning grime off cases/pan while putting her back together... Images to follow etc....

For those that may need.... $14 tool to get the flywheel off, worked like a charm! :thmup:

Image
oldmanrock
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Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu

Post by oldmanrock »

Made some progress, almost there....

Starter Clutch replaced, yup old one is toasted...

Engine Cleaned...

Hate Working on oily/greasy/grimed crap....

Carbs cleaned inside & out...

Water Pump Oil Seal.... Seep hole is where she leaked pass seal...

DIY Flywheel holder for 110 ft/lbs torque....

Now it's install the exhaust, radiator w/coolant and starter her up....
New Pirelli Route rear tire going on as well!

Final completed images later....
OldKawDrvr
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Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu

Post by OldKawDrvr »

Your links don't seem to be working on this site, (at least for me).But I saw your post on KZR. Awesome work, :bowdn: :thmup: You really took that baby down! Very nice work on the exhaust headers. Too bad you can't see them when it's all together. BTW, it looks like you could be the anchor man on the KZR relay.
oldmanrock
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Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu

Post by oldmanrock »

Anyone else able to review...?

OK., shrunk the images down, lets see if this works.... NOPE...
"It was not possible to determine the dimensions of the image..."

Ah well.... Put the header on, no starter clutch slippage, purred right to life! :LvStrk
OldKawDrvr
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Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu

Post by OldKawDrvr »

oldmanrock wrote: Ah well.... Put the header on, no starter clutch slippage, purred right to life! :LvStrk
The most satisfying push of a button you'll ever have! :thmup:
oldmanrock
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Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu

Post by oldmanrock »

:tho: OK trying this image posting from an online image sharing....

Image URL link for exploded view..... Image link for small forum views....

http://postimg.org/image/bdyzo0ecx/
Image

http://postimg.org/image/p48oo4x9p/
Image

http://postimg.org/image/86e9g1d9p/
Image

http://postimg.org/image/k9jl3lobx/
Image

http://postimg.org/image/523lj8wh9/
Image

http://postimg.org/image/yq294fofh/
Image
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doug of so fla
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Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu

Post by doug of so fla »

Photo's came out great!!! :clap: Be sure to post finished product!! Looks like it will be perfect when done.. You will like the XII a whole lot better after you do a job like that, knowing everything is done right... congrats... :clap: :thmup:
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Chris near Kansas City
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Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu

Post by Chris near Kansas City »

Few have ventured so far....

:thmup:
"You only live twice, or so it seems. One life for yourself and one for your dreams...." Nancy Sinatra

"If a man made it, a man can fix it." - Steve in Sunny Fla
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